초록 ▼

Systems and methods for automated non-destructive inspection scanning of the top and bottom aerodynamic surfaces or skins of an integrally stiffened wing box (e.g., a horizontal stabilizer) using surface crawling vehicles. Each system uses dynamically controlled magnetic coupling to couple an extern

Systems and methods for automated non-destructive inspection scanning of the top and bottom aerodynamic surfaces or skins of an integrally stiffened wing box (e.g., a horizontal stabilizer) using surface crawling vehicles. Each system uses dynamically controlled magnetic coupling to couple an external drive tractor to a pair of passive trailers disposed in the interior of the wing box on opposite sides of a spar. The external drive tractor is also coupled to an external NDI scanner, which the tractor pushes or pulls across the surface skin being inspected. The systems allow scanning of both surface skins without turning the wing box over. Each system is modular and can be transported to and easily set up in a building or factory.

대표청구항 ▼

1. A method for scanning a wing box skin, comprising: (a) placing a first tractor vehicle in a position external to the wing box and in contact with the skin;(b) placing first and second trailer vehicles in respective interior spaces of the wing box with a first spar of the wing box therebetween;(c)

1. A method for scanning a wing box skin, comprising: (a) placing a first tractor vehicle in a position external to the wing box and in contact with the skin;(b) placing first and second trailer vehicles in respective interior spaces of the wing box with a first spar of the wing box therebetween;(c) magnetically coupling the first and second trailer vehicles to the first tractor vehicle with the skin therebetween and to each other with the first spar therebetween;(d) coupling a payload platform to the first tractor vehicle in a position external to the wing box, the payload platform comprising a frame and a maintenance tool that is movable relative to the frame;(e) moving the first tractor vehicle along a path that follows the first spar;(f) stopping the first tractor vehicle; and(g) moving the maintenance tool of the payload platform in a first direction relative to the frame of the payload platform while the first tractor vehicle is stopped in step (f). 2. The method as recited in claim 1, wherein during step (g) the maintenance tool of the payload platform moves laterally relative to the first spar. 3. The method as recited in claim 1, further comprising: (h) placing a second tractor vehicle in a position external to the wing box and in contact with the skin;(i) placing third and fourth trailer vehicles in respective interior spaces of the wing box with a second spar of the wing box therebetween;(j) magnetically coupling the third and fourth trailer vehicles to the second tractor vehicle with the skin therebetween and to each other with the second spar therebetween;(k) coupling the payload platform to the second tractor vehicle;(l) during step (e), moving the second tractor vehicle along a path that follows the second spar; and(m) stopping the second tractor vehicle,wherein step (g) is performed while the first and second tractor vehicles are not moving. 4. The method as recited in claim 3, wherein the first and second spars are not parallel. 5. The method as recited in claim 1, further comprising: (h) stopping the maintenance tool;(i) moving the first tractor vehicle further along the path that follows the first spar;(j) stopping the first tractor vehicle; and(k) after step (j), moving the maintenance tool of the first payload platform in a second direction relative to the frame of the payload platform while the first tractor vehicle is stopped in step (j), said second direction being opposite to said first direction. 6. The method as recited in claim 1, further comprising actuating the maintenance tool to transmit beams toward the skin. 7. The method as recited in claim 1, wherein the maintenance tool comprises an array of transducer elements configured to scan in a scan plane, said scan plane being oriented parallel to the first spar. 8. The method as recited in claim 1, wherein the maintenance tool comprises an array of transducer elements configured to scan in a scan plane, said scan plane being oriented perpendicular to the first spar. 9. The method as recited in claim 1, further comprising: placing first, second and third wing box support tools under the wing box, said first wing box support tool being closer to a root end of the wing box than is the second wing box support tool and the third wing box support tool being closer to a tip end of the wing box than is the second wing box support tool, each of the first, second and third wing box support tools being configurable between a first state wherein it supports the wing box and obstructs the payload platform and a second state wherein it neither supports the wing box nor obstructs the payload platform;configuring the first, second and third wing box support tools so that the second and third wing box support tools support the wing box while the first wing box support tools does not;while the second and third wing box support tools are supporting the wing box, moving the first tractor vehicle from a position whereat the payload platform overlies a space between the root end of the wing box and the first wing box support tool to a position whereat the payload platform overlies a space between the first and second wing box support tools;after the preceding step has been performed, reconfiguring the first and second wing box support tools so that the first and third wing box support tools support the wing box while the second wing box support tools does not; andwhile the first and third wing box support tools are supporting the wing box, moving the first tractor vehicle from the position whereat the payload platform overlies a space between the first and second wing box support tools to a position whereat the payload platform overlies a space between the second and third wing box support tools. 10. An apparatus for scanning a wing box skin, comprising: a first tractor vehicle comprising a first frame, a plurality of wheels rotatably coupled to said first frame, a first coupling element, a first plurality of magnets supported by said first frame, a first drive wheel for driving said first tractor vehicle to move, and a first motor for driving rotation of said first drive wheel, said first motor being supported by said first frame; anda first payload platform comprising a second frame, a plurality of wheels rotatably coupled to said second frame, a second coupling element, a first maintenance tool supported by and movable relative to said second frame, and a first actuator for moving said first maintenance tool relative to said second frame, said first actuator being supported by said second frame,wherein first and second coupling elements are coupled to each other. 11. The apparatus as recited in claim 10, wherein said actuator comprises a lead screw and a motor for driving rotation of said lead screw. 12. The apparatus as recited in claim 10, wherein said first payload platform further comprises a second plurality of magnets supported by said second frame. 13. The apparatus as recited in claim 10, further comprising a second tractor vehicle, said second tractor vehicle comprising a third frame, a plurality of wheels rotatably coupled to said third frame, a third coupling element, a second plurality of magnets supported by said third frame, a second drive wheel for driving said second tractor vehicle to move, and a second motor for driving rotation of said second drive wheel, said second motor being supported by said second frame, wherein said first payload platform further comprises a fourth coupling element, said third and fourth coupling elements being coupled to each other. 14. The apparatus as recited in claim 13, wherein said first coupling element is pivotable relative to said second coupling element, and said third coupling element is pivotable and slidable relative to said fourth coupling element. 15. The apparatus as recited in claim 13, wherein said first and second coupling elements form a rotating joint, and said third and fourth coupling elements form a sliding and rotating joint. 16. The apparatus as recited in claim 10, further comprising a second payload platform comprising a third frame, a plurality of wheels rotatably coupled to said third frame, a third coupling element, a second maintenance tool supported by and movable relative to said third frame, and a second actuator for moving said second maintenance tool relative to said third frame, said second actuator being supported by said third frame, wherein said first tractor vehicle further comprises a fourth coupling element, said third and fourth coupling elements being coupled to each other. 17. The apparatus as recited in claim 10, wherein said first maintenance tool comprises a linear array of transducer elements. 18. A system comprising the apparatus as recited in claim 10 and a hollow composite structure, said hollow structure comprising a spar and first and second skins connected by said spar, and said apparatus being in contact with an external surface of said first skin and overlying a portion of said spar, said system further comprising: a first trailer vehicle disposed under said first skin and adjacent to one side of said spar, said first trailer vehicle comprising a third frame, a plurality of wheels rotatably coupled to said third frame and in contact with an internal surface of said first skin, and a second plurality of magnets supported by said third frame, at least one magnet pole of said second plurality of magnets being magnetically coupled through said first skin to a respective magnet pole of said first plurality of magnets; anda second trailer vehicle disposed under said first skin and adjacent to another side of said spar, said second trailer vehicle comprising a fourth frame, a plurality of wheels rotatably coupled to said fourth frame and in contact with an internal surface of said first skin, and a third plurality of magnets supported by said fourth frame, at least one magnet pole of said third plurality of magnets being magnetically coupled through said first skin to a respective magnet pole of said first plurality of magnets,wherein at least one magnet pole of said second plurality of magnets is magnetically coupled through said spar to a respective magnet pole of said third plurality of magnets. 19. A system for performing a maintenance function on a wing box skin, comprising: (a) a hollow composite structure comprising first and second spars and first and second skins connected by said first and second spars;(b) a mobile platform comprising: (i) a chassis comprising first and second chassis parts coupled to each other, said first chassis part overlying a first portion of said first spar, each of said first and second chassis parts comprising a respective plurality of wheels in contact with said external surface of said first skin;(ii) a first drive wheel rotatably coupled to said first chassis part and in contact with said external surface of said first skin;(iii) a first actuator mounted to said first chassis part for causing said first drive wheel to rotate;(iv) a first plurality of magnets mounted to said first chassis part; and(v) a first maintenance tool slidably coupled to said second chassis part, said first maintenance tool being slidable along said second chassis part; and(vi) a second actuator mounted to said second chassis part for causing said first maintenance tool to slide along said second chassis part;(c) a first trailer vehicle disposed adjacent a first portion of an internal surface of said first skin and adjacent one side of said first spar, said first trailer vehicle comprising a second plurality of magnets, at least one magnet pole of said second plurality of magnets being magnetically coupled to a magnet pole of said first plurality of magnets through said first skin; and(d) a second trailer vehicle disposed adjacent a second portion of an internal surface of said first skin and adjacent another side of said first spar, said second trailer vehicle comprising a third plurality of magnets, at least one magnet pole of said third plurality of magnets being magnetically coupled to a magnet pole of said first plurality of magnets through said first skin, and at least one magnet pole of said third plurality of magnets being magnetically coupled to a magnet pole of said second plurality of magnets through said first spar,wherein said magnetically coupled mobile platform and first and second trailer vehicles move in unison when said drive wheel is rotated. 20. The system as recited in claim 19, wherein said first maintenance tool is an inspection unit, said mobile platform further comprises means for measuring an X position and a Y position of said inspection unit, and said system further comprises a pulser/receiver unit operatively coupled to said inspection unit and to said first and second encoding means, said pulser/receiver unit being programmed to perform the following operations: sending control signals to said inspection unit;receiving scan data signals from said inspection unit;receiving X-Y position data signals from said measuring means; andcorrelating said scan data with said X-Y position data. 21. The system as recited in claim 19, further comprising: a plurality of motion script files containing sequences of motion commands and parameters respectively associated with a plurality of motion paths; anda computer system programmed to execute a sequence of commands in a selected one of plurality of motion scripts, said sequence of commands controlling operation of said first and second actuators to cause said first maintenance tool to move along a corresponding selected one of said motion paths in accordance with its associated parameters. 22. The system as recited in claim 19, wherein said chassis further comprises a third chassis part coupled to said second chassis part, said third chassis part comprising a respective plurality of wheels in contact with said external surface of said first skin, said third chassis part overlying a portion of said second spar, wherein said mobile platform further comprises: (vi) a second drive wheel rotatably coupled to said third chassis part and in contact with said external surface of said first skin, said third chassis part being movable along a third motion path when said second drive wheel rotates while in contact with said external surface of said first skin;(vii) a second actuator mounted to said third chassis part for causing said second drive wheel to rotate;(viii) a fourth plurality of magnets mounted to said third chassis part;(ix) a third encoder for measuring a position of said third chassis part along said third motion path, andwherein said system further comprises:(e) a third trailer vehicle disposed adjacent a third portion of an internal surface of said first skin and adjacent one side of said second spar, said third trailer vehicle comprising a fifth plurality of magnets, at least one magnet pole of said fifth plurality of magnets being magnetically coupled to a magnet pole of said fourth plurality of magnets through said first skin; and(f) a fourth trailer vehicle disposed adjacent a fourth portion of an internal surface of said first skin and adjacent another side of said second spar, said second trailer vehicle comprising a sixth plurality of magnets, at least one magnet pole of said sixth plurality of magnets being magnetically coupled to a magnet pole of said fourth plurality of magnets through said first skin, and at least one magnet pole of said sixth plurality of magnets being magnetically coupled to a magnet pole of said fifth plurality of magnets through said second spar. 23. The system as recited in claim 19, wherein said first chassis part is pivotably coupled to said second chassis part, and said third chassis part is pivotably coupled and slidably coupled to said second chassis part. 24. The system as recited in claim 19, wherein said chassis further comprises a third chassis part coupled to said first chassis part, said third chassis part comprising a respective plurality of wheels in contact with said external surface of said first skin, said third chassis part overlying a second portion of said first spar, wherein said mobile platform further comprises: (vi) a second maintenance tool slidably coupled to said third chassis part, said second maintenance tool being slidable along said third chassis part; and(vii) a third actuator mounted to said third chassis part for causing said second maintenance tool to slide along said third chassis part.